http://www.homestead.com/volvo2/240headlight.html

Good site with lots of nice pics.

drill a hole or two in the bottom of the lens assembly. this is the la-Z-boy method.

I recently acquired an 89 240 with a headlight that had water in it. I removed the headlight and used a heat gun to soften the putty in the seam between the body and the lens of the assembly. I also ran a razor blade knife along the seam and finally inserted a screwdriver blade and slowly turned the blade. I had to try several different places before I finally found an area that would start to seperate. Once the two were seperated (don't get in a hurry) I was able to use small scrapeing tools to remove the putty on both halves. I cleaned the inside of the lens and the body. I also used the heat gun to drive out the moisture under the metal reflector in the body half. After everything was clean and dry I used pure silicone caulk in the seam all the way around and then put the two together. I seperated them once more and filled the seam again- this time putting them aside to cure. Make sure you have the seam completely sealed as with silicone I don't think you could ever get them apart again.

Randy